Microwave antenna and method for making same

ABSTRACT

A method for fabricating a microwave horn antenna in which a thermoplastic sacrificial layer is mounted to a thermoplastic horn layer. A heated horn embossing plate having at least one horn shaped embossing element is then moved into the horn layer so that the horn element penetrates through the horn layer and extends partially into the sacrificial layer thus forming a horn opening in the horn layer complementary in shape to the horn element. The horn layer and sacrificial layer are then separated from each other and the horn opening and at least a portion of the back surface of the horn layer is covered with a metal coating. A thermoplastic wave guide layer formed by embossing wave guide channels into the layer is covered with metal and attached to the back side of the horn layer to form the antenna. Alternatively, a portion of the horn and the remaining portion of a microwave channel are formed in both a first and second thermoplastic section. These portions of the microwave guide channel and horn are then coated with a metal material and the sections are secured together in a facing relationship so that the horn portions and wave guide channel portions on both the first and second sections register with each other.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates generally to a microwave antenna andmethod for making the microwave antenna.

II. Description of Related Art

Dedicated short range radar communications (DSRC) of the type used inautomotive vehicles occur at high microwave frequencies, currently about77 gigahertz. Such DSRC systems are utilized not only for anti-collisionsystems, but also as well as other inter-vehicle and vehicleinfrastructure communications. These previously known DSRC systemstypically use microwave antenna arrays with a plurality of spaced aparthorns for additional gain. Furthermore, since such antennas are utilizedin automotive vehicles, a low cost antenna system is highly desirable.

One previously known method for constructing microwave horn antennas ofthe type used in automotive vehicles has been to place a layer ofthermoplastic material in between two hot embossing plates so that oneplate faces a front surface of the layer while a second plate faces theback side of the layer.

The first plate includes one or more horn shaped embossing elementswhile, similarly, the second embossing plate contains embossing elementscorresponding in shape to the wave guide channels for the antenna. Theembossing plates, when heated, are then compressed against thethermoplastic layer so that the horn shaped embossing elements penetratethe thermoplastic layer and ultimately abut against the second embossingplate. Similarly, the wave guide channel elements on the secondembossing plate depress portions of the back side of the thermoplasticlayer to form the wave guide channels so that the wave guide channelsare interconnected with the one or more cones.

Thereafter, both the front and back sides of the wave guide are coveredwith metal by sputtering a metal both onto the cones as well as the waveguide channels. A metal plate is then positioned across the back side ofthe thermoplastic layer so that the wave guide channels are formed inbetween the metal plate and the metallized wave guide channels on theback side of the thermoplastic layer. The horn and wave guide channelsare then further metal coated by electroplating.

A primary disadvantage of this previously known method of fabricatingmicrowave horn antennas, however, is that a certain amount of plasticflash is formed at the intersection of the horn embossing element andthe second embossing plate during the embossing process. Such plasticflash is not only difficult to metallize as required for proper antennaperformance, but also interferes with the overall operation of themicrowave antenna since the flash changes the ideal shape of the conefor optimal microwave performance.

In order to avoid degradation of antenna performance caused by theplastic flash, it has been the previous practice to remove the flasheither with a knife or similar object prior to covering the horn withthe metal coating. The removal of flash in this fashion, however, isimprecise and thus results in overall degradation of the performance forthe antenna. Furthermore, this removal cannot be automated and requiresmanual handling, both of which increase the manufacturing cost.

SUMMARY OF THE PRESENT INVENTION

The present invention provides a method for fabricating a microwave hornantenna which overcomes the above-mentioned disadvantages of thepreviously known methods.

In a first embodiment of the invention, a sacrificial layer ofthermoplastic material is first mounted to the horn layer ofthermoplastic material. The horn layer includes both a front and backspaced apart surfaces and the sacrificial layer flatly abuts against atleast a portion of the back surface of the horn layer.

A heated embossing plate having at least one horn shaped embossingelement is then moved against the front surface of the horn layer sothat the horn element on the embossing plate penetrates through the hornlayer and extends partially into the sacrificial layer. In doing so, theembossing element forms the horn opening in the horn layer which iscomplementary in shape to the horn element on the embossing plate.

The horn layer and sacrificial layer are then separated from each other.The horn opening and at least a portion of the back surface of the hornopening is then covered with a metal coating, preferably by sputtering.

In order to complete the microwave antenna, a wave guide layer ofthermoplastic material defining at least one wave guide channel isfabricated to cover the back side of the horn layer. Preferably, thewave guide layer is formed by moving a heated wave guide embossing platehaving at least one wave guide shaped embossing element against thefront surface of the wave guide layer. In doing so, the embossing plateextends at least partially into the wave guide layer thus forming thewave guide channels. These channels are then covered with a metalmaterial, such as by sputtering.

The wave guide layer and horn layer are then attached to each other. Themetallization of the wave guide channels and horns is then completed byelectroplating.

Since the horns are formed by pressing the horn embossing elementcompletely through the horn layer and partially into the sacrificiallayer, all plastic flash at the signal input end of the wave guide hornis completely eliminated. In doing so, the inlet end of the horn may beprecision formed which enhances the overall efficiency and accuracy ofthe microwave antenna.

In a second embodiment of the invention, at least a portion of the hornand at least a portion of the microwave guide channel associated withthe first horn is formed in a first thermoplastic section having aplanar surface. Preferably, the portions of the horn and microwavechannel are formed by pressing a hot embossing plate into thethermoplastic section.

Similarly, the remaining portion of the horn and remaining portion ofthe microwave guide channel associated with the horn is formed in asecond thermoplastic section having a planar surface. These portions ofthe horn and microwave guide channel are also preferably formed bypressing a hot embossing tool into the planar surface of the secondthermoplastic section. Preferably, the first and second sections areidentical to each other.

Following the fabrication of both the first and second sections, theportions of the horn and microwave guide channels on both the first andsecond sections are covered with metal. Although various methods may beused to achieve this, preferably, the horn portions and microwave guideportions are covered with metal by sputtering.

After metallization of the horn and microwave guide channel portions,the first and second sections are secured together in a facingrelationship so that the planar surfaces of the first and secondsections flatly abut against each other and so that the horn portions onboth sections and wave guide portions on both sections register witheach other. Following attachment of the sections, the metallization ofthe antenna is completed preferably through electroplating.

BRIEF DESCRIPTION OF THE DRAWING

A better understanding of the present invention will be had uponreference to the following detailed description when read in conjunctionwith the accompanying drawing, wherein like reference characters referto like parts throughout the several views, and in which:

FIG. 1 is an elevational diagrammatic view illustrating an initial stepof fabricating the microwave antenna according to a first embodiment ofthe present invention;

FIG. 2 is an end view illustrating a step of the fabrication of themicrowave antenna according to the present invention;

FIGS. 3A-3C are diagrammatic views illustrating the step of embossingthe horn openings in the horn layer;

FIGS. 4A and 4B are diagrammatic steps illustrating the fabrication ofthe wave guide layer according to the present invention;

FIG. 5 is a view taken substantially along line 5-5 in FIG. 4B;

FIG. 6 is a diagrammatic view illustrating the microwave antenna of thepresent invention;

FIGS. 7A and 7B are a diagrammatic view illustrating the initial stepsof fabricating a preferred second embodiment of the present invention;and

FIG. 8 is an elevational diagrammatic view illustrating the assembly ofthe second embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

With reference now to FIGS. 1 and 2, in order to form the microwave hornantenna according to the present invention, a horn layer 20 ofthermoplastic material is provided. This thermoplastic layer 20 includesa planar surface 22 and has a thickness at least equal to the axiallength of the horn for the microwave antenna. Similarly, a sacrificiallayer 24 of thermoplastic material is also provided. The sacrificiallayer 24 includes a front planar surface 26 which flatly abuts againstthe back planar surface 22 of the horn layer 20.

The horn layer 20 and sacrificial layer 24 are mounted together as shownin FIG. 2 so that the surfaces 22 and 26 flatly abut against each other.Any conventional means, such as a mechanical jig, adhesive or the likemay be utilized to temporarily secure the horn layer 20 and sacrificiallayer 24 together.

With reference now to FIGS. 3A-3C, a heated embossing plate 28 having atleast one, and more typically several, horn shaped embossing elements 30is positioned above the front surface 32 of the horn layer 20. Theembossing plate 28, when heated, is moved from the position shown inFIG. 3A and to the position shown in FIG. 3B. In doing so, the hornshaped embossing elements 30 penetrate the horn layer 20. Furthermore,the horn shaped embossing elements 30 are dimensioned so that, uponcompletion of the embossing operation as illustrated in FIG. 3B, theembossing elements 30 not only penetrate through the horn layer 20, butextend slightly into the sacrificial layer 24. The embossing tool 28 isthen removed as shown in FIG. 3 thus leaving the plurality of hornshaped openings 34 in the horn layer 20.

As best shown in FIG. 3, since the horn shaped embossing elements 30penetrate completely through the horn layer 20 and partially into thesacrificial layer 24 all plastic flash around a signal inlet end 36 ofeach horn opening 38 is completely avoided. Instead, the single inletend 36 of each horn opening 38 maintains the precise dimensional size asdefined by the embossing tool and its horn shaped elements 30.

Following the embossing step, the sacrificial layer 24 is separated fromthe horn layer 20 as shown in FIG. 3C. The sacrificial layer 24 is theneither discarded or recycled. Furthermore, in order to facilitate theseparation of the sacrificial layer 24 from the horn layer 20 followingthe embossing operation, it is preferable that the horn layer 20 andsacrificial layer 24 be made of thermoplastic materials that do notreadily bond together.

After construction of the horn layer 20 with the horn openings 38, awave guide layer 40, also constructed of a thermoplastic material, isfabricated to form the wave guide channels for coupling the microwaveenergy to the horn openings 38. As best shown in FIG. 4A, a heatedembossing plate 42 is provided having one or more outwardly protrudingwave guide embossing elements 44. These wave guide embossing elements 44correspond in shape to the desired wave guide channels for the antenna.

The heated embossing plate 42 is moved from the position illustrated inFIG. 4A and to the position illustrated in FIG. 4B in which the waveguide embossing elements 44 contact and partially penetrate a frontsurface 46 of the wave guide layer 40. The wave guide channel embossingtool 42 is then removed.

As best shown in FIG. 5, after the removal of the wave guide embossingplate 42, the embossing plate 42 effectively forms wave guide channels48 in the front surface 46 of the wave guide layer 40. It will beunderstood, of course, that the wave guide channels 48 illustrated inFIG. 5 are by way of illustration only and that the precise shape andsize of the wave guide channels 48 varies dramatically depending uponthe design of the overall antenna.

After formation of both the horn layer 20 and wave guide layer 40 bytheir respective embossing plates 28 and 42, the wave guide channels 48and the horns 38 are coated or covered by a metal preferably bysputtering although different methods may be utilized. At least aportion of the back surface of the horn layer 20 is also preferablycovered with a metal material by sputtering or other conventionalmethods.

With reference now to FIG. 6, the front side 46 of the wave guidechannel layer 40 is then mounted flatly against the rear side 22 of thehorn layer 20 so that each horn opening 38 registers with its associatedwave guide channel 48. The horn layer 20 and wave guide layer 40 arethen secured together by any appropriate means such as an adhesive,mechanical fasteners, chemical bonding, and/or the like.

In order to facilitate the proper alignment between the horn layer 20and the wave guide layer 40, preferably one or more alignment rods 60(FIG. 3B) protrude outwardly from the embossing plate 28 and formopenings in the horn layer 20 at precise known positions. The openingsformed by the alignment rods 60 in the horn layer 20 in turn cooperatewith alignment rods 64 (FIGS. 4B and 5) formed on the wave guide layer40 during the embossing step forming the wave guide layer.

After the horn layer 20 and wave guide layer 40 are secured together asshown in FIG. 6, the wave guide channels 48 and horns 38 are preferablyelectroplated to complete the metallization of the microwave antenna.

From the foregoing, it can be seen that the present invention provides asimple and yet highly effective means to fabricate a microwave antennawhich completely eliminates the plastic flash formed around the signalin the ends 38 of the microwave horns as present with the previouslyknown antenna constructions.

With reference now to FIGS. 7A and 7B, a modification to the presentinvention is shown in which a heated embossing plate 80 having anembossing pattern 82 on its bottom side 84 is positioned above a section86 of thermoplastic material. The embossing plate 80 is then moved intothe section 86 as shown in FIG. 7B such that the embossing pattern isformed in an upper surface 88 of the section 86.

As best shown in FIG. 8, the embossing pattern 82 on the embossing plate80 creates a portion of the microwave horns 90 as well as a portion ofthe microwave guide channels 92 associated with the horns 90 in theplanar upper surface 88 of the first section 86. It will be understood,of course, that the pattern illustrated in FIG. 8 is by way ofillustration only.

Still referring to FIG. 8, a second section 100 is also formed insubstantially the identical fashion as the first section 86. Therefore,a further description thereof is unnecessary. Additionally, preferablythe first section 86 and second section 100 are substantially identicalto each other.

After the fabrication of both the first section 86 and second section100, at least the horn portions 90 and wave guide channel portions 92are initially metallized by any conventional means such as sputtering.Other metallization means, of course, may be used without deviation fromthe spirit or scope of the invention.

The first section 86 and second section 100 are then positioned in afacing relationship so that the horn portions 90 on the first section 86register with the corresponding horn portions 90 on the second section100. Likewise, the microwave guide channel portions 92 on the firstsection 86 also register with the microwave guide channel portions onthe second section 100. The first and second sections 86 and 100 arethen secured together by any conventional means.

After securing the first section 86 to the second section 100, themetallization of the guide channels 92 and horns 90 is completed byelectroplating the horns 90 and guide channels 92. Thereafter multipleblocks of the first section 86 and second section 100 may be assembledtogether to form the microwave antenna with the desired number of hornsand thus the desired gain and directivity of the antenna.

Since the embossing plate 80 used to imprint the embossed pattern ofboth the partial horns 90 and partial wave guide channels 92 in thefirst and second sections 86 and 100 does so without leaving any plasticflash, distortion and attenuation of the microwave signal caused by suchplastic flash is completely avoided. Furthermore, since the entiremicrowave channel is formed of a plastic material other than, of course,the metallization step, the present invention effectively avoids thepreviously employed metal plate together with the attendant cost andweight associated with such metal plates for microwave antennas.

Having described my invention, many modifications thereto will becomeapparent to those skilled in the art to which it pertains withoutdeviation from the spirit of the invention as defined by the scope ofthe appended claims.

1. A method for fabricating a microwave horn antenna comprising thesteps of mounting a sacrificial layer of thermoplastic material to ahorn layer of thermoplastic material, said horn layer having a front andback spaced apart surface, so that one side of said sacrificial layerflatly abuts against at least a portion of said back surface of saidhorn layer, moving a heated horn embossing plate having at least onehorn shaped embossing element against said front surface of said hornlayer so that said horn element penetrates said horn layer and extendspartially into said sacrificial layer thus forming a horn opening insaid horn layer complementary in shape to said horn element, thereafterseparating said horn layer and said sacrificial layer, covering saidhorn opening with a metal coating, fabricating a wave guide layer,attaching said wave guide layer to said back side of said horn layer. 2.The method as defined in claim 1 wherein said covering step furthercomprises the step of sputtering a metal on said horn opening and atleast a portion of the back surface of the horn layer.
 3. The method asdefined in claim 2 wherein said covering step further comprises the stepof electroplating a metal on said horn opening and at least a portion ofthe back surface of the horn layer after said sputtering step.
 4. Themethod as defined in claim 1 wherein said wave guide layer fabricatingstep comprises the steps of moving a heated wave guide embossing platehaving at least one wave guide shaped embossing element against a frontsurface of a wave guide layer of thermoplastic material so that saidwave guide shaped embossing element extends partially into said waveguide layer thus forming wave guide channels in said front surface ofsaid wave guide layer, and covering said wave guide channels with ametal coating.
 5. The method as defined in claim 4 wherein said coveringstep Her comprises the step of sputtering a metal on said wave guidechannels.
 6. The method as defined in claim 5 wherein said covering stepfurther comprises the step of electroplating a metal on said wave guidechannels after said sputtering step.
 7. The method as defined in claim 4wherein said wave guide embossing plate includes at least one cavitywhich forms an alignment post on said wave guide layer following saidmoving step, said post being received in an alignment opening in saidhorn layer during said attaching step.
 8. A microwave horn antennacomprising a thermoplastic horn layer having a front and a back spacedapart surfaces and at least one horn opening which extends between andthrough said front and back surfaces, said horn opening being formed bymounting a thermoplastic sacrificial layer to said back of said hornlayer, moving a heated embossing plate having a horn shaped embossingelement against said horn layer so that said horn shaped embossingelement penetrates through said horn layer and extends partially intosaid sacrificial layer and thereafter separating said sacrificial layerfrom said horn layer, a wave guide layer having a front surface with atleast one wave guide channel, Said horn and said wave guide channelseach having a metal coating, Said front surface of said wave guide layerbeing mounted against said back surface of said horn layer so that saidwave guide channel registers with said horn opening.
 9. A method forfabricating a microwave horn antenna comprising the steps of forming atleast a portion of a horn and at least a portion of a microwave guidechannel in a first thermoplastic section having a planar surface, saidportions of said horn and said microwave guide channel in said firstsection being open to said first section planar surface, forming atleast a portion of a horn and at least a portion of a microwave guidechannel in a second thermoplastic section having a planar surface, saidportions of said horn and said microwave guide channel in said secondsection being open to said second section planar surface, coating saidportions of said horn and said microwave guide channels on both saidfirst and second sections with a metal, attaching said first and secondsections together with said first section planar surface and said secondsurface planar section flatly abutting against each other and so thatsaid portions of said horn and said portions of said wave guide channelsin said first and second sections register with each other.
 10. Themethod as defined in claim 9 wherein said first and second sections aresubstantially identical to each other.
 11. The method as defined inclaim 10 wherein said forming steps each comprises moving a heatedembossing plate against a block of thermoplastic material, saidembossing plate containing embossing elements corresponding to said hornportions and said wave guide channel portions.
 12. The method as definedin claim 11 wherein said coating step comprises the step of sputteringmetal onto said horn portions and said wave guide channel portions ofboth said first and second sections prior to said attaching step. 13.The method as defined in claim 12 wherein said coating step furthercomprises the step of electroplating said horn portions and said waveguide channel portions of both said first and second sections.
 14. Themethod as defined in claim 13 wherein said electroplating step isperformed after said attaching step.